Manufacture of elastic fabric



Patent! Apr. 11,'1939 assi n- Corner: fion, Dover, m1., a corporation o! Delaware Application Septemlr 2, 1936, Serlal No. 99,150.

In France, Great Britain, Ireiand, and

July 20. 1933 24 Claims.

My present invention has for its object the manufacture of fabries and products obtained therefrom, which are made from linear elments, such as described in the copending application 5 Serial No. 99,149 filed on Sept. 2, 1936, and which are woven and treated in such a manner as to be highly impregnable by iiquids and which possess aiter impregnation extremely high qualifies of 'elasticity and strength. My present application is a continuation-in-part-application 0! nm prior application Serial No. 735,314 filed Juiy 16, 1934, and contains not only matter disclosed in said prior application, but also new improvementsrelating thereto.

It is known that the impregnation of fabrics by means of elastic or plastic material or other analogous materials becomes increasingly diflicuit as the fibres ofthe fabric are more tightened against one another, eitherrom the beginning by reason of the high initial twist of the thread or subsequenflmby the manner in which the fabric is made, or flnaily by the swelling 01 the threads at the time of impregnation, or by several, of these causes acting at the same time. 25 Moreover the fabrics formed of threads already say threads having a high twist and which are woven openly so as to have, after a swelling and contracting-oper&fion. the texture of a closely woven fabric, cannot be practically impregnated with elastic or plastic materials. even if the mesh 5' was initiaily so large that there was no suppletirentary transverse compression of the thread by reason of* the contraction of the mesh. The

thread forming such fabrics would have undergone,'during the operation of swelling and contraction, a compression of its own, independent of the shrinking of the mesh which compression would strongly oppose the penetrati0n of the elastic or plastic materiai. To this compression there would be added that due to the swelling of the threads under the effect of the vehicle A fabric made of ordinary threads, that is to Mexleo of the impregnating bath. Such a fabric moreever would. not possess any substantial degree of elasticit.

- The present invention on the contrary makes possible the production of fabrics very readily and under normal conditions of weaving and im x3reghating operation; and the invention embraces both the products. and also the process whereby they are manufaotu1ed.

'Ihe manufacture of such readily impregnated fabrics according to the invention is rendered possible first of ail by the fact that the fabric is constituted not with ordinary threads, but with -the special linear elements so called inverse twists described in the copending application Serial ;Nm 99,149, which are formed each 01 a piuralitv o! rovings which have been 'supertwisted individuafly in one direction -to such an extent .that they cannot be substantially drawn out, and'which have been then assembled togetber by a twisting in the opposite direction !or approximateiy the same number 01 turns as t hat of the individual twist of each r-oving.

. The process according to the invention is essentiali ,hsrna in that, with the said -speciai open linear elements whose fibres do not exert appreciable mutual compression, an open- .mes h fjabric io0sely woven is made, the degree of opening of the linear elements and the initial dimension of the mesh of the.fabric being such that, when the fabric is submitted to a swelling and contracting oxieration without tension by means of nigent such for example as a strong acid or a strong base, the linear elements remain open and approach one-another without the said open elements being appreciably compressed. A v

- In the operation of swellinz and contracting the closing up increases, that is to say the ditference between the extended iength of the linear clament and 'itS apparent length in warp ing treatments.

In order to malte fabrics ot considersble thickness, it is 01 advantage to weave bundles of inverse twists into a. loose mesh fabric, that is to say, bundles each formed ci! a plurality of inverse twists, so that the linear clament constituted by one such bundle has the deslred thickness.

It is to be noted that, instead o! employing a. plain weave, it may be ci. advantage to arrange the layers of inverse twists as a sateen weave.

The swelling and contracting agents for treating the loose mesh fabric may be such as are usually employed (strong acid or strong base) which are capable of transforming more or less completely the cellulose into hydrocellulose without harming it; for example, good results are obtained by treating the loose-mesh tabrlc with caustic soda 015 30 R. et 18 C. for about 15 minutes.

The flrst operation performed on the loosemesh textile fabric consists in treating it without tension by means of a strong swelling and contracting agent such as soda.

In carrying out the contracting and swelling treatment it may be useful to employ a wetting agent, in order that the loose-mesh tabric be fully wetted by the bath in which it is lmmersed. As wetting agent may be employed any wetting agent which is commonly known for theusual treatments of textiles with liquids.

The fabric is allowed to remain in the bath under the conditions described whlch are such that a close-mesh fabrlc is obtained in which however no substantiel compression between the linear elements and between their fibres takes place; afterwards the fabticis removed from the bath and is expressed so that the greater part of the bath may be recovered.

Prefersbly, after having been subjected to the treatment with the bath of contracting and swelling agent, and having been caretully washed, the i'abrlc according tdthe invention is subjected to a boiling treatment. which is carrled ont under the conditions usuel l'or such a treatment in the textile industry, for example with the ald 01 carbonate oi' soda lye, et the high temperature convenient for bofling.

The boiling treatment may be carried out as follows: the fabric, carefully washed, is ziven a boiling by means of a lye et carbonate ot soda ot-3%, to which there is added a soda soap et V 1.5% under a pressure 01 1.5 atm. corresponding to a temperature et 113 0. for 4 hours. The percentaze is calculated always with respect to the weight of dry cotton.

After such boiling treatment. the Jabric preferably is washed with warm water, then with cold water, and atterwards la treated with hydrochloric acid or the lite, then is washed anew and flnally is carefully dried. As an exemple 01 such treatment subsequent to boiling, the fabrlc alter boiling may be.washed wlth warm water at 90 for about 1 hour, 'careiully washed' with cold water, neutralized through a solution of commercial hydrochloflc acid 0! 0.5 B., then again washed ti l1 the chlorides are eliminated. Iinafly the treated fabrlc is carefufly drled so that there remalns only about 7% ci wetness with respect to the weight of the dry cotton. The fabric is then ready for impresnatlon. One ci? its essential characterlsflcs is that it is very easfly impregnated, due to the fact that the linear clements forming it are very open and not appreclably compressed asainst each other.

To make a rubberized fabric according to the invention the tensile strength required 1s first considered at the same time as the thickness required for the fabric. There is taken for example a linear textile element consisting of a speclal non-treated inverse twist such as defined above and corresponding to the diameter required; then a fabric is made having a texture in warp and weft 50% inferior in strength to that required in the ultimate product. The fabric is then subjected to the treatment above described ot contracting and swelling, of boiling, washing and drying and then the acquired properties of the fabrlc are flxed by impregnation with rubber latex. If the impregnation is to take place by means of a solution of rubber or other like impregnating material, drying is performed before impregnation; otherwise it is not necessary to dry it until after impregnation.

The iabric obtained after the successive treatments described above being hlghly impregnable, in order to impregnate it with elastic*or plastic material (rubber, balata, or other materials of the same kind) derived either from latex or from a solution of rubber in a volatile solvent, the im pregnation may be performed in any lmown manner but without exercising tension or compression upon the fabric; for example by simple immersion in a. natural or artificia] suspension et elastic or plastic material, such as rubber latex or even in a solution of these materials in a volatile solvnt. Obviously rinsins and dryings which would normaily be necessary between the severai operations will be performed. As afore said, the impregnation fixes the properties of the fabric, particularly its strength and elasticity.

Preferably the im'pregnation is carried out by immersion of the fabric in a bath oi latex, containing for exemple 40% of dry rubber with the vulcanising agents. The impregnation occurs preferably without vacuum or pressure being applied, in vats or other receptacles which are closed with a cover which is sufllciently tight to prevent evaporaton of the ammonia, which would result in the coagulation of the surface of the bath. After each impregnating operation the ammonia content of the bath is brought to the required degree by adding thereto a solution of commercial ammonia.

Atter the impregnation, the fabric is placed in conditions suitable for coagulatlng the rubber.

4 perature of the drying apparatus be lowered as the fabric dries.

The quantity of water remaining at that time in the fabric will not exceed preferably 4% of the weight of the impregnated fabric.

In most cases, the impregnating treatment. is followed by vulcanization. The fabrlc when impregnated is preserved until it is desired to vulcanize the same, and 1or this purpose is kept preferably in warehouses which are dimly 1lzhted assumed their position of equilibrlum.)

Tiiis fabric is treated with a caustic soda lye 0! 30 136. at a temperature et 18 C. for min:

ntes.

'Ihe fabric swells and contracts but t he warp and wei't threadsdue to the fact that the treatment is eiected without tension and also that the fabric had very open meshesare not substantially compressed aithough the fabric has become a tight textured fabric. that is to say whose threads are close tozether. This new fabric weighs 300 grams per square mette and it has in warp and weit 14 warp threads and 14 weit threads per centmetre. With a strip having a width cl 5 centimetres it has a breakinz strength of 62 kgs., 40% elongation and 30% residuai elasticity.

The -swelling and the contraction of the threads are 30% in warp and weft. Ihere are. 149=5 more threads per centimetre, or 55% increase.'

The weight has become 150 grams plus 55% of 150 grams=l5o+8z grams=232 grams, no account beinc yet taken of the swelling and shortening of the warp and weit. The swelling of 30% of the warp and weit caiculated upon 232 grams results in an increasing of the weight :232 x 30% :69 grams,

making a total of 232 grams+69 trams=30l grains which corresponds to within a gram of the figure stated above resulting from physical tests.

01 boiling, washing, neutralizing, anew washing and drying as has been desciibed above, andf fina1ly to impregnation.

Aiter rubbering by means of latex and after vulcanization the iabrics had 75 kg. strength at breaking upon a band of 5 cm. widthand 50% o! entirely residml elasticity, the strength and the elasticity being flxed at these figures by.the rubber et the impregnation.

It is to be noted that in all cases, given the normal conditions required, it is possible to attain the desired conditions-by a preliminry cal cnlation. Supposing that the conditions required are 75 kgs. tensile strength in bauds of 5 cm. and 0.5 mm. 'thickness, atter impregnation one will take for exampie a 14/2Iinear element. Its diameter D hein; calcuiated by the known method (L bein'z the length and n the number of spirala a dlameter ci D=0.4 mm. will be iound Given that it is possible to obtain by a treatment w'ith soda with a concentration, temperature and duration, such as have been aiven above, a swellinz' bly of the iabrlc ;aiter impregnation, this will permit a final thicknecs oi %mm.=0.52 mm;. the thiokneas required. This compression wiil not harm in any manner the fibres et the fabrlc Then the fabric is subjected to the treatment V because of the absence et compression et the fibres et the fabric during its manufacture. 'Ihe 14/2 thread of American cotton has a tensile strength'of about 700 grams. 'Ihe strength of each 'thread being increased by 50% by the treatment mentioned above, there is.obtalned for each threjad a tensile strength oif 1050 grams. One should ithus'have in mind for the number of threads'to the centimetre threads for a'band oi.5 cm. or 14 threads per cm. As the l'abric increases by 50% in number of war and 'wettthreads by the swelling and contracting treatment of 30%, the initial fabric should be formed with 9 warp and 9 weit threads.

The swelling and the t:ontraction 01 30% produced by the operation eflected in the conditions stated above will thus rsjult in a iabric with 14.

' elast ic or plastic matcflalxsuch,'for example, as

balata or other similar elastic or plastic substances.

The Iabrics according to the invention are, by reason.of their strength and elasticity, adapted to the manufactre ot pneumatic tires.

For the manufacture ct power transmission belts,iabrics according to the invention may be employed in the manne: customanly used for the fabrication 01 thos articles. However, the greatj elasticity of the Iabric and the facility oiE flxingits re s id .l elastiity, and on the other hand the tact that it is necessary to have in the transverse direction 01 the belt only ever so iittle elasticity, make it, possible to. manufacture, with .the iabric' according to the invention, belts which .possess almost no transverse elasticity while havings hixh longitudinal elasticity.

For this Durpose the fabric is caused to undergo 'after such a. tension in the transverse direction oi ,the belt (wett 013 the fabric) that the elasticity 01 the fabric disappears and that the fabric'is' brought bact 'to its original width or even to a larzer width. Then the i'abric is dried and its elstic properties' are thus resulated; thiabfls' are assembled by the known pfl ceues in sufficient number of plies -for obtaifliz m desired thickness. '1his assmbly of fabrisjis'ihen pressed and vulcanised. Before pressing one may. if.desired, regulate the .elasticit in tile direction oi"warp as has been described abcve.

For themanatatu of fabrics for clothing and other :u'xaloxous applications, one will regalate' "pretcrably ,withot any,tension the elasticii}y whichtis .1n this case a:fnndamenta1 ele- What I cltim is l. A :proceas (or the mnu1tme tabric comprlainx :the siens et torminglinear textile .elements very open throuxhort t o penctratlmihy.qnids and substantially without reciprocal :.between the constituent fibres. elenxentsinto a fabric having meshec -ot. s'unir dimensiomflmt when treated with a strong,contflcfln and swellinz agent a cloue mach bric is formed -withont -however -ot elastic- .,with a strong contracting and swelling agent a close mesh fabric is formed without however compressing said linear elements appreiciably, and then treating said fabric with a suitable contracting and swelling agent.

3. Process for the manufacture of elastic fabric comprising the steps oi forming very open linear elements substantiafly-without reciprocal compression between the constituent fibres thereof by individualiy supertwisting a plurality of rovings 'without substantial tension a certain number or turns in one direction and assembflng them by twisting them approximaly the same num ber oi turns in the opposite direction, forming said linear elements into a iabric having large meshes, and treating said iabric with a strong contracting and swelling agent until the linear elements are brought close together without appreciabie compression thereoi.

4. Process for the manufacture of elastic iab.

ric comprising the steps of forming linear textile elements very open throughout to penetration by liquids and substantiafly without reciprocal compression between the constituent fibres, weaving said elements into a fabric having meshes of such dimensions that when treated with a strong contracting and swelling agenta close mesh iabric is formed withcut however compressing said linear elements appreciabi, thon treating said fabric with a suitable contracting and swelling agent, and then impregnating it With an elastic material.

5. Process for the manufacture of elastic fabric comprising the steps of forming linear elements composed of rovings that have been supertwisted a certain number of turns without substantial tension in one direction and assembled by being twistd approximately the same number of ti1ms in the opposite direction, weaving said elements into afabric having meshes of such dimensions that when treated with a strong contracting and sweliing agent a close mesh fabric is formed without however compressing said iinear elements appreciably, then treating said fabric with a suitable contracting and swelling agent and impregnating it with an elastic material.

. 6. Process for the manufacture of elastic tabric comprising the steps 01 forming very open linear elements substantiafly without reciprocal compression between the constituent fibres therecf, iorming said elementsinto a fabric having large meshes, treating said fabric with a strong contracting and sweliing agent until the linear elements are brougbt close together without ap preciable compression .thereoi, and impregnating said fabric with an elastic material.

7. Process for the manufacture of elastic fabric comprising the steps of individualiy super- -t-wisting a plurality cf rovings without substantial tension a certain number of tums in one direction and twisting them together approximately the same number of turns in the opposite direction, threby forming open linear elements substantially without reciprocal compression between the constituent fibres thereof, iorming said linear elements into a fabric having large meshes, treating said fabric with a strong contracting and swelling agent until the linear ele- 5 ments are brought close together without appreciable compression thereof, and impregnafing said fabric with an elastic material.

8. Process for the manufacture cf elastic fabric comprising the steps of forming open linear 10 elements substantially withot reciprocal compression between the constituent fibres thereof, formihg said elements into a tabric having large meshes, treating said fabric with a strong contracting and swelling agent until the linear ele- 15 ments are brought close together without appreciable compression thereof, impregnating said fabric with a vulcanizable material and vulcanizing the same.

9. Process for the manufacture ci el astic fab- 20 ric comprising the steps .oi formir open linear elements substantiel? without reciprocal bompression between the constituent fibres thereoi, forming said elements into a fabric having large meshes, and treating said fabric with a strong contracting and swelli'ng agent until said linear elements are brought close together without appreciable. compression thereof and the cellulose of their component fibres is converted into hydroceliulose, and impregnating said fabric with an 3@ elastic matexial.

10. Process for the manufacture of an elastic fabric which consists in forming open linear elements substantiafly without reciprocal compression between the constituent fibres thereof, form- 35 ing said elements into a tabric having large meshes, treating said fahric with a strong contracting and sweiling agent until the linear elements are brought close together without appreciablecompression thereoi, inipregnating the 40 iabrlc with an eiastlc material and drying the impregnated iabrlc under tension.

11. A process for the manufacture oi elastic fabric comprising the steps =of forming linear textile elements very, open throughout to 'pene- 45 tration by liquids and substantially without reciprocal compression between the constituent fibres, weaving said elements into a iabric hav= ing'meslnes of such dimensions that when treated with a strong contracting and Sweliing agent a close mesh iabric isformed withoutimweves transversely compressing said linear elements appreciabiy, then treating said fabric witbout tension with a suitable contracting and swelling agent added with a wtting agent, and subiecting said febric to a bofling treatment, to washing and drying.

12. In the manufacture o! elastic iabric formingp linear elements composed of rovings that.

have been super-twisted a certain number ofi cc tums without substantiel tension in one direstien and assembled by being twisted approximately the same number -of turns in the opposite direction. weaving said elements into a fabric having meshes cf such dimensions that when treated with a .strong contracting and swelling agent a close mesh iabric is formed without however-compressing said linear. elements appreciably, and then treating without tension said fab- 4 ric with a suitable contracting and swelling agent added with a wetting agent, and subjecting said fabric to a boiling treatment. to washing and drying.

13. Process'tor the manufacture cf elastic fabric comprisingthe steps ci forming very open linear elements substantiafly without re'ciprocal compression between the constituent fibres thereof by individually supertwisting a plurality 01 rovings without substantiel tension a certain number of turns in one direction and assembflns them by twisting them approximately the same number 01 turns in the opposite direction, forming said linear elements into a fabric having large meshes, and treating said fabric until the linear elements are brought close together without appreciabie compression thereoi with a strong contracting and swelling agent added with a wetting agent, and subjecting said l'abric to a boiling treatment, to washing and dl'ing.

14. Process for the manufacture of elastic fabric comprising the steps of forming linear textile elements very open throughout to penetration by liquids and substantially without reciprocal compression between the constituent fibres, weaving said elements into a iabric having meshes of such dimensions that when treated with a stron contracting and swelling agent a close mesh fabric is formed without however compressing said linear elements appreciably, then treating sald fabric with a suitable contracting and swelling agent added with a wetting agent, and subjecting said iabrlc to a boiling treatment, to washing and drying and then impregnating it with an elastic material.

15. Process for the manufacture ot elastic fabric comprising the steps of forming linear clements composed oi rovings that have been supertwisted a certain number of tums witbout substantiel tension in one direction and assembled by being twisted approximately the same number of turns in the opposite direction, weaving said elements into a iabric having mesbes oi such dimensions that when treated with a strong contracting and swelling agent a close mesh fabrlc and drying and impregfiating it'with an elastic material.

16. Process for the manufacture of elastic fabric comprising the steps of forming very open linear elements substantiafly without reciprocal compression between theconstituent fibres thereof, iorming said elements into a fabflc havi g large meshes, treating said fabrlc until the linear elements are brought close together without l preciable compression thereof with a stro1i8 contracting and swelling agent added with a vetting agent, and subjecting sait! iabrlc to rboiling treatment, to washing and drying and impregnating said iabric with an e1astic materiai.

17. Process for the manufacture oielastic fabrie comprising the steps of individually supertwisting a plurality cf roving: wlthout substantia1 tension a certain number-o! turns in one direction and twisting them 'togetber approxi-' mately the. same number of turbs in the opposite direction, therebyiorming open linear clements substantially without reciprocal compression between the constituent fibres thereot, forming sais! linear elements into a iabric having large meshes, treating said fabrlc until the linear elementg are brought close together without appreciable compression thereof witba strong contracting and swelling agent addedwith a wetting agent, and subjecting said fabrlc to a boiling treatment,'to washing and drying and impreg-;- natin8 said Iabric with an elastic matertal.

18. Processfor the manufacture of elastic fabric comprising the steps of forming open linear elements substantiafly without reciprocal compression between the constituent fibres thereof, 1orming said elements into a fabric having large meshes, treating said fabric until the linear clements are brought close together without appreciable compression thereof with a strong contracting and swelling agent added with a wetting agent, and subjecting said fabric to a boiling treatment, t0 washing and drying, impregnatng said fabric with a vuicamzable materiai coagulating the same, drying it, cutting the selvages 01 the iabrlc so as to prevent the same Irom bulging, and subjecting the fabric to stretching and vulcanization.

19. Process for the manufacture of elastic fabric comprising the steps of forming open linear elements substantiall without reciprocal compression between the constituent fibres thereoi, forming said elements into a fabric having large mteshes, and treating said fabric with a strong contracting and swelling agent added with a wetting agent until said linear elements are brought close together without appreciabie compression thereof and the cellulose of their component fibres is converted into hydrocellulose, subjecting the i'abric to a boiling treatment, to washing and drying and lmpregnating said fabric with an elastic material, coagulating the same and drying it and cutting the selvages of the fabric so as to prevent the same from bulging.

20. Process for the manufacture of an elastlc fabric which consists in forming open linear elements substantiafly without reciprocal compression between the constituent fibres thereoi, forming said elements into a fabric having large meshes, treating said fabric until the linear elements are brought close together without appreciable compression thereof wlth a strong contracting and swelling agent added with a wetting agent, then subjecting the fabrlc to a boiling treatment, to washing and drying, impregnating the fabrlc with an eiastic material and drying the impregnated i'abric under tension.

21. An elastic textile product composed of textile linear elements very open throughout and substantially without reciprocal comprsion between the constituent fibres, said linear elements being. formed into a fabric having meshes of such dimensions that they are in contact with each other without appreciably compressing each other andbeing thoroughly impregnatd and united together by an elastic substance which fills the interstices between the constituent fibres and binds them into a dense, strongiy cohesive and highly compressible product.

22. An elastic textile product formed of fibrous r linear elements composed of supertwisted rovings in a very open condition united by a twist in the reverse direction to that of the individual rovings which are substantiaiiy without reciprocal compression between the constituent fibres, said linear elements being formed into a fabric of such close weave that they are in contact with each other but without appreciably compressing each other and being thoroughly impregnated and united together by an elastic substance which fillsthe interstices between the constituent fibres and binds them into a strongly cohesive an highly compressible product.

23. A thick elastic fabrlc formd of bundles oi flbrous linear elements composed of supertwlsted rovings in a very open condition united b a twist in the reverse direction to that of the individual roviflgs which are substantiafly without reciprocal compression between the constituent fibres, said linea.r elements being formed into a. fabric of such close weave that they are in contact with each other but witbout appreciably compressing each other and being thorougtfly impregnated and united together by an elastic substance which fllls the interstices between the constituent fibres and binds them into a. strongly cohesive and highly compressible product.

24. An elastic textile pmduct formed of, fibrous linear elements composed each of two rovings o! si.2.5 (French si) supertwisted so as to have each a total twist of about 200 turns in one direction and united bya. twist of about 200 turns, so that there is no substantial compression between the constituent fibres, in the reverse direction to that of the individual twist, said linear eiements' being formed into a. fabric of such close weave tiiat they are in contact with each other but without appreciably compressing each other and -being thoroughly impregnated and united together by an elastic substance which fills the interstices between the constituent fibres and binds them into a. strongly cohesive and highly compressible product.

LON SYLVAIN MAX LEJENE. 

